Metal founding



Nov. 17, 192 1,561,924 Y A. M. HENRY METAL FOUNDING Filed Jan. 23, 1924Patented Nov. 17, 1925.

. UNITED STATES PATENT OFFICE.

nueusws m. HENRY, or BaooxLYmNEw YoRK, ASSIGNOR TO WILLIAM w.wE1T-' J'LING, TRUSTEE, or COLLEGE POINT, NEW YORK.

METAL FOUNDING.

Application filed January 23,1924. Serial No. 688,031.

To allv whom it may concern Be it known that I, AUGUSTUS M. Human,

. a citizen of the United States, and a resident of the city of NewYork, borough of Brooklyn, in thev county of Kings and State of New.York, have invented certain new and useful Improvements in MetalFounding, of which the following is a full, clear, and eX-= actdescription.

The present invention relates to the art of casting metals ofcomparatively high melting temperatures (say of over 1000 degrees F.),and particularly theferrous metals; and aims to provide a novel andvaluable method of an apparatus for (a) rapidly and economi'callyproducing ferrous castings of any desired form, while insuring (b) thatsuch castings always will include, merely as the result of the castingoperation itself, a particular metallurgical characteristic essential ifnot highly desirable in various industries,

An important object of the present invention, in' the. latter regard, isto form the castformed of or ing, say in a fixed as contradistinguishedfrom a rotary mold, and in what may be truly termed a'permanent mold,and at the same time treat theflcasting as it solidifies so that thesame will be case-hardened where contacted by all or some of the wallsof the mold cavity,.the novel apparatus aforesaid being comprised of alining or partial-lining for the mold cavity having the characteristicsdescribed'immediately below. j

Another object is to provide a method and apparatus as above, whereinthe mold is g has its cavity lined or faced with a-material which ispractically as inexpensive and as easy to machine smoothly and nicely toshape, material is made up'of masses of granular components socompacted, naturally or artificially, as to be as tenaciously cohesiveas' iron or steel butyet a materialadapted to be machined, or pressed(as to accomplish such compacting) into a mold or mold-part not havingthe liability of a similar iron or steel part to crack, chipand distortfrom molecular rowth as the result of repeated heat-s ocks, i. e., asthe resultof repeated casting operations,thus truly providing apermanent casting mold; which material may be absolutely depended on togive up some of its own content to the contacting superficies of themolten metal impacted against the mold by the pouring force as is ironor steel; which at each casting operation but not enough thereof topreclude the mold from being employed for making a great number ofcastings having only absolutely negligible variations of contour, bulkand weight; such donated content constituting the carbonaceous matterfor coacting with the heat of the metal incident to its molten state,thereby to predetermine that the casting when ejected from the mold andmerely allowed to cool on the floor of the foundry will be caseharden'edaccording to the invention; and which material will not, like iron orsteel, deeply chill the casting as an iron or steel mold always does.Such a material, I have discovered, is? carbon, preferably denselycompacted; such for instance, as is used for making carbon-electrodesfor electric arc lamps or for making. the commutator brushes fordynam'os, motors and the like.

To explain the practical and salient distinctions between a chilling anda case-hardening of a ferrous casting: When such a casting ischilled,the term is used, herein and indeed generally, to describe what happensto the superficial layer of a fairlylarge mass of cast iron when suchmass is cast and such layer is solidified against a metal mold.

Said layer, obviously, has the same carbon content as the rest of thecasting, exce t that the layer has its carbon in the combine form andthe carbon of the mass of the casting underlying such layer is largelyor wholly graphite. On the other hand, case-hardening as hithertopracticed, has involved (a) the making,-usually if not always in asandmold, of a soft iron casting, that is, a casting having therein amore or less uniform distribution of carbon largely or wholly in thegraphitic form throughout; and (b) the application to the superficiesof'such casting,

some time after removal'from the mold and different and greater carboncontent than the rest of the casting; as contradistinguished chilledlayer has the same carbon content'as the inner mass of the casting,andfurther, the carbon of the chilled layer is carbon in the combinedform and so resulting in a layer very brittle and of little toughnessand absolutely no malleability.

As a result of the fact, then, that the present invention provides acasting which is case-hardened merely, and not chilled as above, whenformed against the mold lining.- of the present invention, there isprovided by the invention a method and apparatus par ticularly adapted,thereby to attain a' special object of the invention, for making rapidlyand economically, and in a permanent mold, ferrous metal castings of anyparticular shape desired, and in a mold which does not have to berotated or moved during the cast ing operation.

An important advantage of the invention. is the fact, as l havediscovered, that the case-hardening of the casting may be kept almostimpalpable as to thickness, and negligibly resistant to ordinarymachining, if

.the casting is ejected from the mold when still uite hot.

Re erring now to the accompanying draw- I ing wherein is illustrated apreferred embodiment of such apparatus and an illustrative method ofcasting facilitated thereby according to the invention,

Figure 1 is a perspective view of a casting to be formed, purposelyshown as a simple slab to clarify the disclosure;

Figure 2 is a vertical longitudinal section taken through the apparatus;and

Figure 3 is an end elevation of the apparatus.

It will be understood that the invention vpreferably contemplates theprovision of a mold lining, whether such lining is really an integralpart of a single member form ing the entire cope or drag structure asshown in the drawing) or whether such lining is a separate lining for ametallic or other suitable cope or drag structure,such lining includinga plurality of pre-formed shaped blocks or pieces, hereinafter calledblocks, constructed of a material having the qualities hereinabovedescribed.

Thus, referring now to the details of the drawing, the casting of Figurel is adapted to he made in the casting cavity 4,- of the mold of Figures2 and 3, the molten metal being introduced through the tunnel or gate 5.

0 Such gate 5 is formed part of a "I I a p14. termed mock o of thearoresaid;

menses such block really constituting the entire cope, since the -metalencircling structure 7 is merely provided for mounting a pair of handles8 at opposite ends of the mold for lifting the cope clear of theunderlying drag when the casting has set. 1

The drag is shown at 9 and really comprises a large flat slab of thematerial aforesaid; since the cupped metal plate or structure 10constitutes merely a foundation in; the cup of which the drag propersets by gravity. a

Of course, such a very simple drag 9 is permitted in the case of asimple casting like that shown in Figure 1.

Attention is directed tothe fact that the drag proper 6, although onepiece of said material, provides not only the gate 5 but the formingsurfaces for all the six sides of the casting except the bottom thereof.

It is recommended that the lower bounding edge of the cope 6 be providedwith transverse half-round grooves as indicated at 11, to facilitatetheescape of the gases of congelation. stood that the dimensions of thesegrooves are very greatly exaggerated in the drawing, since they areactually most minute, or at least so minute that the molten metal willnot enter the spaces provided by the same.

As to the apparatus shown, obviously variations may be freely resortedto within the scope of the appended claims.

In said claims, wherever a mold or mold part is characterized aspermanent, there is meant merely that said part is of a material or soconstructed that the part will not be so injured by a single castingoperation as to ity having a permanent facing formed of a I It will, ofcourse, be underbe useless for a second casting operation, as

surface of a preformed block of a material having the qualities of beingable to be pressed to such shape from granular com ponents, and ofhaving the ability to withstand repeated heat-shocks asthe result ofrepeated casting o erations.

AU USTUS M, HENRY.

v DISCLAIMER, 1,561,924.-Augastus M. H mm Brooklyn, N. Y. METALFOUNDING. Patent dated November 17, 1925. Disclaimer filedFebri'iary 1,1926, by the assignce, T'ViZZ 'am Hereby enters this disclaimer to thatpart bf the claim in, said specification Which is in the followingWords, to wit: V V p 1. A mold including a l'l'lQ ldlng cavity having apermanent facing formed of a 7 surface of a preformed block of amaterial having the qualities of being able to be pressed to such shapefrom granular components, and of having the ability to withstandrepeated heat-shocks as the result of repeatedcasting operations.

Further, inasmuch as this disclaimer is based on the discovery ust madethat United States Letters Patent No. 1,501,337, granted said Henry July15', 1924.

contains in claim 2 thereof a claim to subject matter which mightconceivably be held to cover (although that is not now conceded)vsubstantially. the same subject matter as that to which is directedthe'hereinabove quoted claim 1 of said Letters Patent No. 1,561,92:t,your petitioner also enters this disclaimer to that'part of the term ofsaid Letters Patent No. 1,561,924 as shall overlap or extend beyond thedate of expiration of the term of said Letters Patent No. 1,501,337.

[Oyficz'al Gazette February 16, 1926.]

